Interlocking panel system

ABSTRACT

A system is provided having a number of interlocking panels for constructing a building. Each of the panels has a linear concave member protruding from a first surface and a linear convex member protruding from a second surface. The convex member is configured to slide linearly into the concave member and become locked therein against separation in a direction perpendicular to the line of sliding. The convex member is positioned adjacent to a first edge of each panel and the concave member is positioned adjacent to a second edge of each panel in a manner that when assembled, a first assembled panel is offset from a second assembled panel, creating a lapped series. The panels additionally have holes for being fastened to a building frame.

FIELD OF THE INVENTION

The present invention relates to the field of building materials, and more particularly to a system of exterior building panels for roofing and siding.

BACKGROUND OF THE INVENTION

Traditionally, exterior roofing and siding building materials have mainly been designed and applied in a manner intended to shed rainwater and keep the building interior dry. The building frame is typically first clad with a sheathing material, e.g. plywood. A barrier layer, e.g. tarpaper or Tyvek® plastic sheeting, is then applied to seal the building against wind and water. Last, a layer of shingles for the roof and lapped siding, e.g. wood planks or vinyl strips, is applied. The outer layer of roofing or siding is applied by starting from the bottom, attaching a first row, and then mounting a second row in a manner for the lower portion of the second row to overlap the upper portion of the first row. With this configuration of lapped exterior panels covering the building frame, rain that falls on the panels runs down to the ground and does not enter the building interior.

While this traditional building panel system is effective in protecting the building interior from rain and other precipitation, weather systems often involve significant wind. Wind usually blows horizontally and occasionally at various angles, including vertically. In many areas of the world, and especially in recent years, “nor'easters,” hurricanes, cyclones, and tornadoes occur. These storms include high velocity wind driven in odd directions. With the changes that have been occurring to the global climate, these storms are more violent and more frequent than in the past. When high velocity wind and water hit a building in a horizontal direction, the lower edge of roof shingles may be lifted and rain is driven into the building. If the wind velocity is high enough, the roof shingles are torn off the building. In extreme cases, wind can remove siding planks from the building frame. The end result is often serious damage to the building and its contents that is upsetting to the inhabitants and costly to repair.

SUMMARY OF THE INVENTION

The present invention provides an interlocking panel system for buildings that overcomes the drawbacks of the known roofing and siding materials. The invention system includes a series of panels having a tongue along first edge on a first surface and a mating groove along a second edge on a second surface, the second edge being parallel to the first edge. The tongue and groove are configured to engage and disengage by sliding in a direction parallel to the first and second surfaces only, preventing disengagement by lifting in a direction perpendicular to the surface. A series of mounting holes are formed along a line near the second edge to affix the panel to the building frame members, preferably without the need for plywood sheathing. The various configuration of panels of the present invention include an edge panel, a plate panel and a ridge panel.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention is best understood in conjunction with the accompanying drawing figures in which like elements are identified by similar reference numerals and wherein:

FIG. 1 is a side elevation schematic view of a building frame with a roof formed of panels according to the present invention.

FIG. 2 is a perspective view of a plate panel of the invention positioned for being engaged with an edge panel of the invention.

FIG. 3 is a perspective view of a pair of ridge panels of the invention.

FIG. 4 is a partial end view of an upper panel and a lower panel showing the interlocking tongue and groove of the invention in juxtaposed positions.

FIG. 5 is a plan view of a building portion with interlocking panels of the invention mounted thereto in staggered configuration.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now to FIG. 1, a building frame 10 is illustrated in side elevation view without sheathing sheets, and with the roof enclosed according to the invention. Rafters 12 are mounted at an exemplary angle S. The process of applying the interlocking panel system of the present invention begins by placing an edge panel 18 in contact with the lower end of each rafter set 12 with the downwardly directed flap of each edge panel 18 resting against the angular exposed end of rafters 12. A series of fasteners F are inserted through holes formed along a line adjacent to the upper edge of each edge panel 18. A tier of plate panels 20 are interlocked with edge panels 18 as will be described below. A series of fasteners F are inserted through holes formed along a line adjacent to the upper edge of plate panel 20. Fasteners F are preferably screw fasteners to securely hold edge panel 18 to rafters 12. Fasteners F may alternatively be adhesive coated nails. As illustrated, plate panels 20 are substantially planar; if the slope S of rafters 12 is relatively steep in comparison to the run R of each plate panel 20, the upper edge of plate panel 20 may be formed at an upward angle to better accommodate fasteners F. Run R is typically in the range of 6 to 10 inches. Whereas there is no sheathing applied to rafters 12, workers assembling the panel system of the invention to a building frame are able to install sequential tiers of plate panels 20 while standing on horizontal joists 14, avoiding the danger of standing on sheathing assembled to sloping rafters 12. As additional tiers of plate panels 20 are mounted to rafters 12 approaching the peak of the roof, the final tiers must be mounted by roofers positioned on the roof. Finally, ridge panels 22 and ridge flashing 24 are mounted to close the roof surface. As seen, the completed panel system creates a lapped surface covering.

Referring now to FIG. 2, an edge panel 18 and a plate panel 20 are depicted in position for being assembled to one another. Edge panel 18 is formed by extrusion with a rectangular planar portion 38 and a rectangular lip portion 40 in angular relation to one another, a concave linear interlocking member such as groove 42 and a series of mounting holes 44. As noted above, edge panel 18 is mounted to the building rafters 12 (see FIG. 1) with lip portion 40 in intimate contact with the exposed angular end of each rafter 12 and a series of fasteners inserted through holes 44. Additional edge panels 18 are mounted to rafters 12 to cover the entire edge of building frame 10 (FIG. 1). Referring further to FIG. 2, plate panel 20 is formed with a rectangular planar portion 28, a convex linear interlocking member such as tongue 30, a concave linear interlocking member such as groove 32, and a series of mounting holes 34. Holes 34 of plate panel 20 and holes 44 of edge panel 18 are preferably separated from one another by a distance to match conventional building methods, e.g. a spacing between adjacent holes of 8 inches will match commonly used building frame component spacing of 16 or 24 inches. Tongue 30 is positioned adjacent to one edge of plate panel 20 on a lower surface, and groove 32 is positioned adjacent to an opposed edge of plate, panel 20 on an upper surface. As shown, the edge portion of plate panel 20 that is adjacent to tongue 30 extends a minimal distance beyond tongue 30 to reduce the potential lifting effect of a high velocity wind. Tongue 30 of each plate panel 20 is configured to engage and lock into a groove 32 of an adjacent edge panel 18 or sequential plate panel 20. Therefore, to cover higher sections of rafters 12 (FIG. 1), a first plate panel 20 is moved laterally in the direction indicated by arrow A to slide tongue 30 of plate panel 20 into engagement with groove 42 of previously mounted mating edge panel 18, and fasteners are inserted through mounting holes 34. Whereas tongue 30 is formed on the lower surface and groove 32 is formed on the upper surface of plate panel 20, plate panel 20 cannot be incorrectly mounted, and mounting holes 34 are always positioned toward the top of the building. Holes 34 are preferably positioned along a line parallel to groove 32, between groove 32 and the adjacent edge of plate panel 20. According to known building practice, it is preferred to stagger the edges of successive rows of panels to minimize the chance of water infiltration as will be seen in FIG. 5. The length L of edge panel 18 is substantially equal to length L of plate panel 20. Length L is typically in the range of 3 to 6 feet. Depending on the intent of the manufacturer, the panels comprising the present invention may be formed with a uniform thickness throughout or with thinner portions and intermediate longitudinal ribs for rigidity.

Referring now to FIG. 3, a pair of ridge panels 22 are illustrated as positioned juxtaposed to one another in substantially the orientation shown in FIG. 1 as they are mounted to a typical roof structure. Ridge panels 22 are made to length L of 3 to 6 feet. Ridge panels 22 are formed with a tongue 50 on lower surfaces and adjacent to an edge thereof. Ridge panels 22 have a channel 26 formed along an opposite edge. Channel 26 is configured for the insertion of a bent or rounded ridge flashing component 24 (see FIG. 1) or, alternatively a ridge vent, by sliding the component laterally into channels 26. After a ridge flashing or a ridge vent is put in place, the roof covering is basically complete. To further secure the panels and reduce the chance of water infiltration, the lines of juncture between each adjacent panel may be sealed with caulking compound or similar weather-resistant material.

Referring now to FIG. 4, an enlarged partial side elevation of an upper plate panel 20 a having tongue 30 depending downwardly therefrom and a lower plate panel 20 b having groove 32 extending upwardly therefrom are illustrated opposed to one another. As depicted, the opening within groove 32 is sized and shaped to snugly and slidingly receive tongue 30. Tongue 30 and groove 32 are each preferably formed as an equilateral trapezoid in cross sectional view. Alternate shapes for tongue 30 and groove 32, e.g. circular or “T” shaped, are considered within the scope of the present invention. According to the preferred embodiment of the invention, all panel components described are formed by the process of extrusion. The preferred material for forming the panels described herein is aluminum, although other materials susceptible to extrusion, including other metals and plastic resins, are deemed to be included in the principles of the present invention. With tongue 30 inserted in groove 32 by sliding along their respective lengths, and fastened to the building frame, the assembly is substantially permanent. Removal of any intermediate panel of the present invention involves dismantling the panels from the top of the building surface to the level of the problem panel.

Referring now to FIG. 5, a plan view of a portion of a building is shown as covered with the interlocking panel system of the invention. As seen, a first row of edge panels 18 is followed by a number of rows of plate panels 20. At the upper end, a row of ridge panels 22 is assembled and the covering is completed with a ridge flashing or ridge vent 24. The common practice of staggering each succeeding row of panels has been employed to avoid continuous aligned joints from the top to the bottom and thus minimize the chance of water infiltration. Whereas the illustrated and described example relates to a roof covering system, the major features of the invention are readily adaptable to exterior vertical wall coverage.

As described above, the interlocking panel system of the invention provides a series of building exterior panels that are easy to install and is more secure and protective than currently known shingles, planking or extruded vinyl siding.

While the description above discloses preferred embodiments of the present invention, it is contemplated that numerous variations and modifications of the invention are possible and are considered to be within the scope of the claims that follow. 

1. An interlocking panel system, comprising: a. a series of substantially rectangular panels, each having an upper surface, a lower surface, a first edge and a second edge, the second edge residing substantially parallel to the first edge; b. a first member formed on the upper surface of each panel adjacent to the first edge; c. a second member formed on the lower surface of each panel adjacent to the second edge; and d. the second member of each panel configured for lockingly engaging the first member of a mating second panel.
 2. The interlocking panel system described in claim 1, wherein the first member protrudes outwardly from the upper surface and the second member protrudes outwardly from the lower surface.
 3. The interlocking panel system described in claim 2, wherein the first member is concave and the second member is convex in cross section and formed of a size to snugly slide in the first member in a direction substantially parallel to the first and second edges.
 4. The interlocking panel system described in claim 3, wherein the first member is in the shape of an open trapezoid in cross section and the second member is in the shape of a solid trapezoid in cross section.
 5. The interlocking panel system described in claim 1, wherein the planar panel is formed with a series of holes passing transversely therethrough.
 6. The interlocking panel system described in claim 5, wherein the holes are formed along a line that is substantially parallel to the first and second edges.
 7. The interlocking panel system described in claim 6, wherein the line along which the holes are formed is closer to the first linear edge than the first member.
 8. The interlocking panel system described in claim 1, further comprising an edge panel having a first substantially planar portion with an upper surface and a second planar portion oriented at an angle to the first planar portion and a first member formed on the upper surface, wherein the first member is formed to lockingly receive the second member formed on the lower surface of the plate panel.
 9. The interlocking panel system described in claim 8, wherein the first member is in the shape of an open trapezoid in cross section.
 10. The interlocking panel system described in claim 8, wherein the planar portion is formed with a series of holes passing transversely therethrough.
 11. The interlocking panel system described in claim 10, wherein the holes are formed along a line that is substantially parallel to a line of intersection between the first and second planar portions.
 12. The interlocking panel system described in claim 11, wherein the line along which the holes are formed is closer to the first linear edge than the first member.
 13. The interlocking panel system described in claim 1, further comprising a substantially planar ridge panel with a first edge and a second edge, the ridge panel formed with a second member formed parallel and adjacent to the first edge and a channel formed parallel and adjacent to the second edge.
 14. The interlocking panel system described in claim 13, wherein the second member of the ridge panel is configured to lockingly engage the first member of the plate panel.
 15. The interlocking panel system described in claim 13, wherein the channel is configured and positioned to receive a ridge flashing or a ridge vent. 